Silicone Polymer Layer with Embedded Metal Traces
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Solution Overview
Problem
There is a need for a soft and biocompatible polymer layer with high insulation properties containing embedded very fine metal traces, and an economical and ecological process for manufacturing such polymer layers.
Innovation Solution
A process involving applying a polymer layer on a substrate, thermal treatment, irradiation with an excimer laser, immersion in an autocatalytic bath for metallization, and additional thermal treatments to embed metal traces within a silicone-containing polymer layer, using oxide particles like SiO2 and metal ions for enhanced mechanical behavior and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polymer layer is applied on a substrate and thermally treated, then the polymer provides insulation and structural integrity, but the polymer alone cannot provide embedded metal traces for electrical connectivity
Solution Approach 1:
The patent combines polymer material with metal traces in a single integrated layer, where the polymer provides insulation and structural integrity while the metal traces provide electrical connectivity. This merging of two previously separate functions into one layer resolves the contradiction between insulation reliability and electrical connectivity adaptability.
Solution Approach 2:
The invention uses composite materials consisting of polymer matrix material combined with metal traces. This composite structure allows the material to simultaneously provide both insulating properties from the polymer and electrical conductivity from the metal traces, eliminating the need for separate layers and resolving the technical contradiction.
2Manufacturing precision
If traditional metallization processes are used, then metal traces can be deposited on polymer surfaces, but the process is complex and not environmentally friendly
Solution Approach 1:
The patent segments the metallization process into distinct stages: first applying the polymer layer with embedded metal particles, then thermally treating to embed the metal traces, and finally applying a top coating. This segmentation allows each step to be optimized independently and simplifies the overall process compared to traditional multi-step metallization.
Solution Approach 2:
The invention incorporates metal particles within the polymer layer during the initial application stage, before final thermal treatment. This preliminary action of embedding metal particles in the polymer matrix simplifies subsequent processing steps and reduces manufacturing complexity compared to post-deposition metallization methods.
3Strength
If oxide particles are added to the polymer, then mechanical strength and protection are improved, but the polymer composition becomes more complex
Solution Approach 1:
The patent adds oxide particles to specific regions of the polymer layer where enhanced mechanical strength and protection are needed, rather than uniformly throughout the entire polymer. This localized addition of oxide particles provides strength enhancement while minimizing the increase in overall compositional complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively produces a flexible, biocompatible polymer layer with embedded metal traces, offering high insulation and mechanical strength while being economical and environmentally friendly, with improved adhesion and protection of the metallized silicone layers.
Implementation Method 1
irradiating at least one surface area of the polymer with a light beam emitted by an excimer laser
Implementation Method 2
immersing the irradiated polymer in at least one autocatalytic bath containing ions of at least one metal, and metallizing the polymer
Data Source
AI summary
The present invention provides a process for embedding at least one layer of at least one metal trace in a silicone-containing polymer, comprising:a) applying a polymer layer on a substrate;b) thermally treating the polymer;c) irradiating at least one surface area of the polymer with a light beam emitted by an excimer laser;d) immersing the irradiated polymer in at least one autocatalytic bath containing ions of at least one metal, and metallizing the polymer;e) thermally treating the metallized polymer;f) applying a polymer layer covering the thermally treated metallized polymer; andg) thermally treating the metallized covered polymer.The present invention further provides a polymer layer comprising silicone containing oxide particles of SiO2, TiO2, Sb2O3, SnO2, Al2O3, ZnO, Fe2O3, Fe3O4, talc, hydroxyapatite or mixtures thereof and at least one metal trace embedded in said polymer layer.The present invention further provides a flexible electrode array comprising silicone containing oxide particles of SiO2, TiO2, Sb2O3, SnO2, Al2O3, ZnO, Fe2O3, Fe3O4, talc, hydroxyapatite or mixtures thereof and at least one metal trace embedded in said polymer layer.